Apple MacBook Air mid 2009 Service Manual
Service Source
MacBook Air
(original, Late 2008, Mid 2009)
Updated: 9 December 2009
© 2009 Apple Inc. All rights reserved.
Apple Inc.
© 2009 Apple Inc. All rights reserved.
Under the copyright laws, this document may not be copied, in whole or in part, without the
written consent of Apple.
Every eort has been made to ensure that the information in this document is accurate. Apple is
not responsible for printing or clerical errors.
Apple
1 Innite Loop
Cupertino, CA 95014-2084
USA
+ 1 408 996 1010
www.apple.com
Apple, the Apple logo, Mac, and Macintosh are trademarks of Apple Inc., registered in the U.S. and
other countries.
ii
MacBook Air
Contents
Manual Updates 6
Updated 9 December 2009 6
Updated 31 August 2009 6
Updated 9 June 2009 6
Updated 28 October 2008 7
Introduced 30 January 2008 7
Basics
General Information 9
Overview 9
Model Comparison 10
Quick Tour 12
New Parts and Procedures 14
General Module Notes 18
Support Tools 18
Tools 19
Take Apart
Bottom Case 22
Removal Procedure 23
Serial Number Transfer Instructions 25
Reassembly Procedure 26
MacBook Air Bottom Case Kit 28
Battery 29
AirPort/Bluetooth Card 34
Speaker Assembly 38
Removal Procedure 39
Reassembly Procedure 42
Port Hatch Assembly 44
MagSafe Assembly 47
Hard Drive/SSD 50
iii
Removal Procedure 52
Replacement Notes 59
Thermal Module and Logic Board Combined 60
Thermal Module and Fan 64
Removal Procedure 65
Replacing the Thermal Paste 70
Reassembly Procedure 73
Logic Board 76
Display Assembly 80
Audio Flex Cable 87
Input Devices (IPD) Board Flex Cable 91
AirPort/Bluetooth Card Flex Cable 94
Top Case with Keyboard 97
Additional Procedures
Replacing Keycaps 100
Trackpad Button Set Screw Adjustment 116
Trackpad Button Shim Installation 120
MacBook Air SuperDrive 124
Troubleshooting
General Information 134
Liquid Submersion Indicators 134
How to Use the Symptom Charts 135
Wire and Flex Cables 135
Hardware Diagnostics 136
Sharing Discs with Remote Disc 139
Reinstalling software using Remote Install Mac OS X 141
Reinstalling software using the MacBook Air SuperDrive 142
MacBook Air Firmware Updates 145
Software Troubleshooting Tips and Tools 145
MacBook Air 45W MagSafe Power Adapter Compatibility 147
Troubleshooting Steps 148
iv
Symptom Charts 151
How to Use the Symptom Charts 151
Startup 151
Battery 157
AirPort/Bluetooth Card 159
Bluetooth 161
Display 161
Hard Drive 162
Apple Remote 163
Infrared Receiver 164
Built-in Camera 165
Keyboard 166
Microphone 167
Modem (External) 167
USB Port 168
MagSafe Power Adapter 169
Sound 170
Trackpad 171
Trackpad Button 172
Video 173
Miscellaneous Symptoms 174
Block Diagram 176
MacBook Air (Late 2008) and MacBook Air (Mid 2009) 176
MacBook Air (original) 177
Views
Exploded Views 180
MacBook Air (Mid 2009) 180
MacBook Air (Late 2008) 181
MacBook Air (original) 182
Screw Chart 183
Screw Maps 185
v
Manual Updates
Updated 9 December 2009
Updated Troubleshooting chapters:
General Information: added section about Clamshell Service Diagnostic (CSD)•
Hardware Symptoms: “Power-On Self Test (POST) Error Codes”: added section about 9 beeps •
at start-up
Hardware Symptoms: “Power, but No Video”: modied step #3 to include Clamshell Service •
Diagnostic (CSD); “AirPort is not recognized”: added note to include CSD
Hardware Symptoms: “System shuts down intermittently”: modied step #5 by adding the •
sentence “Change the IPD ex cable before changing the IPD board.”
removed links to Service Diagnostic Matrix (diagnostics are available from Service Source)•
Updated 31 August 2009
Updated chapters:
Display Assembly: added information about magnetic attraction plates.•
Screw Chart: added new part number 922-9172•
Updated 9 June 2009
Added information for new model, MacBook Air (Mid 2009).
Added new chapters for:
Trackpad button set screw adjustment•
Trackpad button shim installation•
Updated chapters:
Basics: General Information: added Mid 2009 model to comparison chart, updated info about •
MacBook Air SuperDrive
Troubleshooting Hardware Symptoms: added section for Trackpad Button, added information •
about Notebook Battery and Adapter Diagnostic, added details about how to respond to
certain ASD error codes, updated all kBase hyperlinks
Hard Drive/SSD•
Thermal Module and Fan•
Exploded Views: added chart for Mid 2009, corrected 2 part numbers on Late 2008, •
corrected 1 part number on original
MacBook Air — Manual Updates 6
Updated 28 October 2008
Added procedures and additional information for MacBook Air (Late 2008), including:
Fan removal without removing the thermal module•
Updated chapters:
Basics General Information•
Speaker Assembly•
Hard Drive/SSD•
Thermal Module and Fan•
Troubleshooting General Information•
Exploded Views•
Screw Maps•
Added information or references for:
Audio board incompatibility•
Hard drive and ex cable incompatibility•
Liquid submersion indicators•
Mini DisplayPort•
Introduced 30 January 2008
MacBook Air — Manual Updates 7
Service Source
Basics
MacBook Air
© 2009 Apple Inc. All rights reserved.
General Information
Overview
Components in the MacBook Air are smaller and more integrated than many other Macintosh
portables; thus, a watchmaker’s nesse is crucial when handling repairs. Likewise, the MacBook
Air’s new system architecture requires troubleshooting methodology specic to its design.
Because there are fewer parts, repair can seem deceivingly simple. Pay close attention to
warnings and cautions throughout the procedures in this manual to avoid repair issues.
MacBook Air Basics — General Information 9
Model Comparison
Main differences between the MacBook Air models:
Mid 2009 Late 2008 original
Microprocessor
Frontside bus
System RAM
Mass Storage
I/O Ports
Liquid Submersion
1.86GHz
2.13GHz
1.066GHz 1.066GHz 800MHz
2GB DDR3 (xed) 2GB DDR3 (xed) 2GB DDR2 (xed)
120GB HDD 4200 SATA
128GB SSD SATA
Analog Audio Out
Mini DisplayPort Out
USB
Yes Yes No
Indicators
Some MacBook Air accessories:
45W MagSafe Power Adapter• — While it has the same MagSafe interface as all Intel-based
notebooks, the adapter’s DC plug is more streamlined to t under the curved bottom case.
1.6GHz
1.86GHz
120GB HDD 4200 SATA
128GB SSD SATA
Analog Audio Out
Mini DisplayPort Out
USB
1.6GHz
1.8GHz CTO
80GB HDD 4200 PATA
64GB SSD PATA CTO
Analog Audio Out
micro-DVI Out
USB
Mini DisplayPort to DVI adapter• (MacBook Air (Late 2008) and MacBook Air (Mid 2009)
Micro-DVI adapters• (MacBook Air (original) — Micro-DVI to VGA and Micro-DVI to DVI adapters
MacBook Air Basics — General Information 10
MacBook Air SuperDrive• – An external USB slot-loading SuperDrive, solely bus-powered, works
only with MacBook Air and must be connected directly to a powered USB port on the computer
itself or on an Apple LED Cinema Display. It will not function through any other hub.
USB Ethernet Adapter• – Allows connection to an Ethernet network. The USB Ethernet Adapter
was sold separately for the original and Late 2008 models, but was included with the Mid 2009
model. The adapter looks similar to the Apple USB modem. You can dierentiate between them
by inspecting the ports: the USB Ethernet Adapter uses an RJ-45 connector with eight contacts,
and the USB Modem uses an RJ-11 connector with two contacts.
MagSafe Airline Adapter• – Allows connection to an airline seat power port of any portable
computer with a MagSafe power port.
MacBook Air Basics — General Information 11
Quick Tour
Following is a quick tour of major features and important repair steps when servicing a MacBook
Air. Please see the specic repair sections to obtain full details on servicing that part.
Basic features
Ports
MacBook Air Basics — General Information 12
Keyboard features
MacBook Air Basics — General Information 13
New Parts and Procedures
Accessing the components
Remove the bottom case to access the components.
Note: Before resting the unit on the workbench, make sure the work area is clear of all debris and
contaminants to avoid damaging the display housing.
Serial number
The system serial number is etched into the bottom case (shown below). It is centered just below
the regulatory markings. See the bottom case section for information on serial number transfer.
MacBook Air Basics — General Information 14
Bottom case angles and curves
Warning: The bottom case screws are inserted at an angle. When reinstalling these screws make
sure you have inserted them at that appropriate angle. Before turning the screw into the boss,
make sure the threads are properly aligned. Use the screwdriver to seat the screw at the correct
angle, and then turn the screw backward (counterclockwise) until you feel the threads “click” into
place. Otherwise, you can damage the screw boss which is part of the top case.
The front edge of the bottom case has ve fragile metal clips that t into ve overhanging tabs
on the top case. Be sure to remove and reinstall the bottom case at a 30º angle.
MacBook Air Basics — General Information 15
A map of the major modules in the MacBook Air (MacBook Air (original) shown)
A – Battery
B – Speaker D – Port hatch F – Thermal module H – Flex bracket J – Display (hinge)
C – AirPort/
Bluetooth card
E –Hard drive G – MagSafe port I – Logic board
MacBook Air Basics — General Information 16
The MacBook Air contains an internal-only battery that is not accessible from the exterior and is
serviceable by authorized Apple service providers only.
Unlike previous systems, when you remove the bottom case, power is still available to the
logic board. Before any further work, disconnect the battery from the logic board connector.
WARNING: Because the battery is internal and connected to the logic board via cable, it MUST BE
DISCONNECTED before performing service procedures. If you fail to do so, live current from the
battery will short circuit the components and render the logic board and/or LVDS cable unusable.
Cables and Connectors
Many cables and cable connectors are very delicate and require specic removal procedures.
Also, new, environmentally friendly Halogen-free materials tend to be stier and less pliable, and
thus require careful handling to avoid damage.
Sleep Sensor
The sleep sensor is located to the left of the sleep indicator light. Like the MacBook Pro, the
magnet is in the display assembly, but since this system is so thin, it is possible to trigger the
sleep sensor with external magnets. For example, when you stack a MacBook Air one on another,
the sleep magnet in the bottom system’s display assembly will trigger the sleep sensor on top.
Battery Icon
A new battery icon, with a triangle and exclamation point inside it means the battery is not
performing to specications (low capacity). It informs the user to have the battery replaced.
Display Repair
Display replacement is with a whole clamshell service part only.
MacBook Air Basics — General Information 17
General Module Notes
Module name Notes
Combo AirPort/Bluetooth card Both functions are on a single card.
Hard drive/SSD This part comes with shock mounts pre-applied, including foam pad and
rubber ring (snubber) and ex cable. Do not remove any of these parts.
Battery, lithium ion Not a user-installable part. Handle with care as the enclosure is not
designed to withstand being dropped.
Power adapter, 45W The connector is compatible with other Intel-based MacBook and
MacBook Pro units. However, with only a 45W rating, it has limited
capability to charge or even start up MacBook and MacBook Pro models.
Logic board Logic boards have soldered-on RAM.
Display clamshell The clamshell contains the display, built-in camera, ambient light sensor
and microphone. The LVDS cable carries data signals for the display
video, camera, and ambient light sensor.
MacBook Air SuperDrive,
external
Top case w/ keyboard The top case houses the keyboard, backlit panel, LED, and (IPD) Input
Thermal module Metal heatsink. The fan is attached on the MacBook Air (original).
Speaker assembly Speaker assembly contains a mono speaker. The audio board and audio
MagSafe port assembly This MagSafe connector is compatible with all the other MagSafe
Port hatch assembly The port hatch assembly includes the hatch, ports, and ex cable. The
Audio board
The external MacBook Air SuperDrive only works with the MacBook Air.
Other systems can see the drive itself but cannot load the media.
Devices board. The IPD board provides control logic for the trackpad on
the top, which is calibrated to the top case. The values are stored on the
IPD board. Thus, the two are a matched set. Do not disconnect any ex
cables from the IPD board other than the main IPD cable to the logic
board. All other ex cables connect to parts that are not replaceable.
cable are replaceable separately.
adapters. However, the overmolding on those adapters causes the
system to sit unevenly, resulting in stress to the DC connector cable.
ex cable connects to the audio board to provide analog audio out.
Important: The MacBook Air (Late 2008) and MacBook Air (Mid 2009)
use the same audio board, but it is NOT compatible with the audio
board in the MacBook Air (original). A mismatched board results in no
audio out. The board is located in the speaker assembly.
Support Tools
MacBook Air has an optional external USB SuperDrive that can be purchased separately. This
option allows you to use the Mac OS X Install Disc 1 tools such as Disk Utility and password reset.
You can also reinstall system software.
However, MacBook Air Mac OS X Install Disc 1 also comes with software drivers to share an
optical disk drive on another machine. This remote machine can be a Macintosh running Mac OS
X v10.4.10 or later, or a PC running Windows XP or Windows Vista.
With Remote Disc installed, you can share content of DVDs or CDs, or restore system software
and applications over AirPort or through an Ethernet connection (facilitated by a separate USB
Ethernet adapter). In both cases, the two computers must be on the same subnet.
MacBook Air Basics — General Information 18
Migrate data (Mac only)
via AirPort Remote Mac OS X software
via USB Ethernet Remote Mac OS X software
via USB Hard Drive Time Machine software
Install application software, use disk-based tools (Disk Utility, Reset Password)
via MacBook Air SuperDrive Use Mac OS X Disc 1 or application Disc
via AirPort through remote Mac/Windows system Use Mac OS X Disc 1 or application Disc
with Mac OS X Remote Disk software
via Ethernet (with USB adapter) through
remote Mac/Windows system
Re-install system software
via MacBook Air SuperDrive Use Mac OS X Disk 1
via AirPort through remote Mac/Windows system Use Mac OS X Disc 1 with Mac OS X
via Ethernet (with USB adapter) through
remote Mac/Windows system
Use Mac OS X Disc 1 or application Disc
with Mac OS X Remote Disk software
Remote Install software
Use Mac OS X Disc 1 with Mac OS X
Remote Install software
Tools
Servicing the MacBook Air requires the following tools:
Clean, non-marring work surface•
ESD wrist strap and mat•
Multi-compartment screw tray (such as a plastic ice cube tray)•
#000 Phillips screwdriver (magnetized)•
#00 Phillips screwdriver (magnetized)•
Torx T6 screwdriver (magnetized)•
Black stick (nylon probe 922-5065) or other non-conductive nylon or plastic at-blade tool•
Display Repair Fixture (922-8538)•
Cosmetic cover kit (076-1284)•
Gasket kit (076-1285)•
Suction cup (922-8252)•
Thermal paste (922-7144)•
Alcohol pads•
Kapton tape (922-1731) •
Fine-point felt-tip permanent marker•
Standard #2 graphite pencil•
Ruler or straight edge•
Needle-point metal probe•
Needlenose pliers•
Tweezers•
Apple keyboard and mouse (for troubleshooting)•
MacBook Air Basics — General Information 19
Electrostatic Discharge (ESD)
Use a properly grounded ESD wrist strap and mat when working on the inside of the computer.
Service Manual Component Photos
In this manual, graphics or photos are intended to help illustrate procedures or information only.
Some photos may show dierent levels of disassembly, board colors, congurations, or computer
congurations than the computer you are working on.
Kapton® Tape Note
New Halogen-free Kapton tape is used to secure cables and connectors where necessary.
During disassembly, note any Kapton tape use and locations—reapply in the same manner. Do
not over apply or build up tape on top of old tape; space tolerances are tight and build up or
extraneous use of tape may cause pressure on other components.
Cable Routing Note
With the MacBook Air’s thin enclosure height, the placement of parts and wiring is more critical
than ever before. During disassembly, note the cable routing. Reassemble in the same manner.
Verify that cables do not route over components when they should route into lower positions or
channels. Verify that the cables are not strained or applying pressure to other components.
Screw Measurement Note
All screw measurements given are the specied full length. Actual measured lengths may vary.
MacBook Air Basics — General Information 20
Service Source
Take Apart
MacBook Air
© 2009 Apple Inc. All rights reserved.
Bottom Case
Tools
This procedure requires the following tools:
ESD wrist strap and mat•
#00 and #000 Phillips screwdrivers (magnetized)•
Black stick (nylon probe 922-5065) or other non-conductive nylon or plastic at-blade tool•
Preliminary Steps
This procedure requires placing the unit upside down on its display housing. Always use a clean,
debris-free static mat to avoid scratches and other cosmetic damage to the unit.
Part Overview
MacBook Air Take Apart — Bottom Case 22
Removal Procedure
Caution: Each screw boss leading from the top case to the bottom case is angled at a dierent
pitch; thus, the angle at which you drive or loosen the screws must correspond accordingly.
Remove ten Phillips #000 screws, starting from the top center and moving outward in a 1.
circular fashion in both directions.
Note: See the screw map in the Views chapter for the exact placement and size of each screw.
MacBook Air Take Apart — Bottom Case 23
Use your ngernails to grip the edge of the bottom case in the rear corners near the display 2.
hinge, or use a black stick as a wedge to gently pry up the bottom case a few millimeters—
enough to grab the edges with your ngers. You may need to pull with slightly more force
on the right side to lift the corner near the MagSafe adapter port.
Pivot the rear edge upward a few inches to a 303.
º
angle. At that same angle, pull the bottom
case outward from the front edge of the top case to preserve the integrity of the front clips.
MacBook Air Take Apart — Bottom Case 24
Serial Number Transfer Instructions
Important Notes:
When replacing the bottom case of a MacBook Air, retain the customer’s original bottom •
case until the repair is complete.
Before installing the replacement bottom case, transfer the serial number from the original •
bottom case to the replacement.
Locate the serial number on the top center of the bottom case (near the vent holes), etched 1.
below the regulatory markings as below. You may need a magnifying glass to read the
characters.
Note: In a bootable system, you can also nd the serial number in “About this Mac” or Apple
System Proler. If the bottom case of the customer’s unit has been previously replaced, see
the subsequent steps for the intended nal written location.
CAUTION: Take great care in deciphering the small typeface of the etched serial number on the
bottom case. It is imperative that you transfer the correct alphanumeric characters. Keep in mind
that Apple serial numbers always use the numbers 1 and 0 instead of the Roman letters “I” and “O.”
On the 2. inside surface of the replacement bottom case, use a ne tip permanent marker to
write the original serial number clearly and legibly in uppercase box letters in the location
below. Look in this location for the serial number on a previously replaced bottom case.
MacBook Air Take Apart — Bottom Case 25
Reassembly Procedure
While holding the bottom case at a 301.
tabs on the top case before lowering into place. Make sure no cables are pinched (e.g., the
AirPort/Bluetooth antenna assembly on the right side and the microphone cable in the rear).
º
angle, insert the clips on its front edge into the
Caution: Each screw boss leading from the top case to the bottom case is angled at a dierent
pitch; thus, the angle at which you drive or loosen the screws must correspond accordingly.
Before actually turning the screw into the boss, make sure the threads are properly aligned.
Use the screwdriver to seat the screw at the correct angle, and then turn the screw backward
(counterclockwise) until you feel the threads ‘click’ into place. You may need to do this a few
times to get the exact thread placement. If you feel resistance, back the screw out and start
again. Failure to do so can strip the boss and render the entire top case unusable.
MacBook Air Take Apart — Bottom Case 26
Insert ten #000 Phillips screws in the following order, paying close attention to the angle. If 2.
922-8337 (2)
7.9 mm
922-8330 (2)
5.4 mm
922-8328 (6)
3 mm
a particular screw does not seem to mate easily with its screw boss, set that screw aside and
try another of the same size. It should take little eort to screw it in.
Quick Test
Before restarting the system to verify the repair, check for structural and cosmetic integrity by
performing the following tests:
Hold the unit rmly in both hands and gently rock it back and forth; then carefully turn the •
unit over, listening for any loose components or connectors.
Place the unit on a clean, at surface and check for wobble.•
MacBook Air Take Apart — Bottom Case 27
MacBook Air Bottom Case Kit
Note that the kit #076-1317 includes seven new screws (one of which is a spare) along with the
bottom case. Unlike the original bottom case screws, the replacement screws (922-8587) have
a shoulder under the head (see photo below). To accommodate the shoulder, the diameter of
correlating screw holes in the replacement bottom case has increased from 2.2mm to 2.6mm.
Procedure
During removal of an original bottom case, discard the six existing 3mm screws shown 1.
below. These will be replaced by the shoulder screws included in the kit.
When reinstalling the new shoulder screws, make sure the head of the screw sits ush with 2.
the bottom case after installation.
Quick Test
Check for consistently even spacing around the perimeter where the bottom case meets the •
top case.
Check that the unit sits evenly when it is placed on a at surface. You may need to loosen •
and tighten the shoulder screws to properly align the bottom case.
If despite the above adjustments the unit continues to sit unevenly, adjust the enclosure •
alignment by placing the unit on a at surface with the display open to 90º. Apply rm, even
pressure on the right and left sides of the palm rests to level the footing of the machine.
MacBook Air Take Apart — Bottom Case 28
Battery
Tools
This procedure requires the following tools:
ESD wrist strap and mat•
#00 and #000 Phillips screwdrivers (magnetized)•
Black stick (nylon probe 922-5065) or other non-conductive nylon or plastic at-blade tool•
Preliminary Steps
This procedure requires placing the unit upside down on its display housing. Always use a clean,
debris-free static mat to avoid scratches and other cosmetic damage to the unit.
Before you begin, remove the bottom case.
CAUTION: The battery must be disconnected from the logic board before proceeding further.
Failure to do so is likely to result in irreparable damage to expensive components such as the
logic board and/or LVDS cable.
Part Location
MacBook Air Take Apart — Battery 29
Removal Procedure
Disconnect the battery cable connector from the logic board, taking care to keep the cable 1.
connector at when pulling it out of its mate. Use your thumb on top and a black stick
beneath to prevent too much bend in the cable. An alternative is to use your index ngers
(and nails) to grab the sides of the connector and pull straight out, level with the board.
Note: Halogen-free cables and connectors are delicate. Handle with care to avoid damage.
MacBook Air Take Apart — Battery 30
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